Dual core mattress

ABSTRACT

A dual-core mattress with removable and replaceable components of different firmness which can be configured to have different heights and which allows the cover to be removed and washed. The upper portion of the mattress can be removed and replaced.

INTRODUCTION/BACKGROUND

Common mattresses include integrated spring mattresses, such as those with chain spring nets and independent pocket springs. Such conventional mattresses have an integrally sutured internal arrangement and can be divided into pure innerspring mattresses, brown spring mattresses, foam and innerspring mattresses, and spring and latex mattresses.

Conventional mattresses are non-replaceable, non-removable and washable, and cannot be cleaned easily. During long-term use, dust and human dander will continue to be deposited on the mattress fabric and inner cushion materials, which may breed bacteria and mites that can endanger the health of users. According to manufacturer specifications, mattress should be considered for replacement after about five years of use, though the lifespan of a mattress is generally more than ten years. Replacing a mattress this frequently results in a high cost to the user.

In addition, mattresses with a fixed internal configuration and structure cannot meet the needs of users who may simultaneously need mattresses having a different firmness. Such mattresses therefore lack the flexibility for users to choose a mattress suitable for their own comfort when used by two people.

SUMMARY

There remains a need for a mattress that can be replaced, washed, detached, and easily adjusted and replaced. The present mattress design fulfills this need by providing modular and standardized mattress components, which can be separated and replaced to reduce the user's cost. The use of modular components also makes it more convenient for the user to clean, dry, and replace a mattress and to provide different comfort levels.

The present dual core mattress includes a removable upper cover, an upper mattress layer below the upper cove, and a bottom mattress layer below the upper mattress layer. The upper cover has an upper cover zipper portion which extends around the lower periphery of the upper cover on a lower peripheral edge and includes downwardly extending zipper teeth. The upper mattress layer is positioned below the upper cover and lies on the upper surface of the bottom mattress layer. The bottom mattress layer further includes a waterproof material on the upper surface, an upper strip tape with an upper positioning zipper portion, and a lower strip tape with a lower positioning zipper portion. The upper positioning zipper portion and upper strip tape extend around the periphery of the bottom mattress layer at an upper end, and the lower positioning zipper portion and lower strip tape likewise extend around the periphery of the bottom mattress layer but vertically below the upper strip tape. In this way, the upper cover zipper portion can be removably secured to the upper positioning zipper portion when the upper mattress layer is positioned on the upper surface of the bottom mattress layer, and can be removably secured to the lower positioning zipper portion when the upper mattress layer is positioned on the upper surface of the bottom mattress layer, thereby allowing the dual core mattress to be have two different vertical heights.

The upper and lower mattress layers can be made from different materials and have a different firmness. In one embodiment, the upper mattress layer comprises two separate pieces, so that each piece can be formed from different materials and have a different firmness. For example, the upper mattress layer pieces can each be made from a material selected from the group consisting of gel memory foam, high-resilience foam, and natural latex cotton. The bottom mattress layer on the other hand can comprise high-resilience foam, chain net springs, or pocketed coils.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the present mattress with the outer cover partially removed.

FIG. 2 is an exploded perspective view of the mattress of FIG. 1.

FIG. 3 is a perspective view of the removable outer cover of the mattress of FIG. 1.

FIG. 4 is a perspective view of the upper replaceable mattress portion of the mattress of FIG. 1.

FIG. 5 is a perspective view of the bottom portion of the mattress of FIG. 1.

FIG. 6 is a perspective view of an illustration showing different combinations of the upper replaceable mattress portion in the present mattress.

FIG. 7 is a perspective view of one embodiment of the present mattress.

FIG. 8 is a perspective view of the mattress of FIG. 7 with the outer cover partially removed.

FIG. 9 is a perspective view of another embodiment of the present mattress.

FIG. 10 is a perspective view of the mattress of FIG. 9 with the outer cover partially removed.

The reference numbers in the drawings designate the following components of the present appliance:

Reference Number Component 01 removable and replaceable upper cover 02 upper cover zipper 03 upper mattress layer (e.g., gel memory foam) 04 waterproof material layer 05 upper mattress assembly positioning zipper 06 upper strip tape 07 lower mattress assembly positioning zipper 08 lower strip tape 09 bottom layer of the mattress (e.g., high- resilience foam, chain net spring, or pocketed coil) 10 left side upper layer (e.g., replaceable gel memory foam or natural latex cotton mattress) 11 right side upper layer (e.g., replaceable gel memory foam or natural latex cotton mattress) 12 right side 13 left side 14 top side 15 bottom side 16 upper surface 17 lower surface

DETAILED DESCRIPTION

The present invention provides a modular mattress having components which are standardized, detachable and replaceable in order to reduce the long term cost of the mattress. The present mattress is also convenient for the user to maintain, including easier drying and replacement. In addition, a user of the present mattress can experience different a firmness and/or mattress height with the present mattress assembly in order adjust the mattress for the user's comfort, which can be accomplished by changing or removing one or more mattress components. Firmness can be measured according to measures used in the industry, for example according to ASTM standard F1566 or by Indentation Force Deflection (IFD) Testing according ASTM standard D3574 (promulgated by ASTM International), and mattresses with different firmnesses preferably differ in firmness by at least 5-10% or more.

One embodiment of the present dual core mattress is shown in FIGS. 1-5. As shown in FIG. 2, the mattress is divided into three modules, namely a removable and washable upper cover 01 (FIG. 3), a replaceable upper mattress layer 03 (FIG. 4, or 10 and 11 in FIG. 6), and a bottom mattress layer 09 (FIG. 5). The fabric of the upper cover 01 is washable and replaceable. The upper cover 01 has an outer, upper surface 16 and a lower surface facing the upper mattress layer 03, and around the lower periphery of the upper cover 01 is an upper cover zipper 02 comprising downwardly facing zipper teeth attached to a lower peripheral edge of the upper cover 01, or to a piece of strip tape (the part of the zipper made from fabric or other material and to which zipper teeth are secured) which is secured to the upper cover 01. The upper cover zipper 02 can engage and be zipped with an upper mattress assembly positioning zipper 05 or a lower mattress assembly positioning zipper 07 as described below.

The upper mattress layer 03 is paced on a bottom mattress layer 09, as shown for example in FIGS. 1 and 2. In order to secure the upper mattress layer 03 to the mattress assembly, the upper cover 01 is placed over the upper mattress layer 03, and upper cover zipper 02 is secured to upper positioning zipper 05, which comprises upwardly facing zipper teeth that can mesh with the downwardly facing zipper teeth of upper cover zipper 02 (such as through the use of a zipper pull and slider). The upper positioning zipper 05 is attached to an upper strip tape 06 which extends around the periphery of the bottom mattress layer 09 and is secured to the bottom mattress layer 09 at an upper end of the bottom mattress layer. The upper cover zipper 02 likewise extends around the periphery of the lower end of the upper cover 01. The upper cover zipper 02 and upper positioning zipper 05 can be unzipped to allow the upper cover 01 to be removed from the present mattress and either washed or replaced with another cover.

The upper replaceable mattress 03 (FIG. 4) is not secured to the other components of the mattress or is reversibly secured (i.e., removed without damaging the upper mattress layer 03) so that it can be replaced, for example with a mattress layer formed from a different material having a different firmness. The upper mattress layer 03 can alternatively comprise two or more different pieces 10, 11, as shown in FIG. 6. FIG. 6 illustrates the placement of a single upper mattress layer 03 (shown at the top left) onto a bottom mattress layer 09 (middle left), after which an upper cover 01 is placed on top to complete the mattress. On the right side of FIG. 6, two mattress layers 10 and 11 (top right) are placed onto a bottom mattress layer 09 (middle right), after which an upper cover 01 is placed on top to complete the mattress. The two mattress layers 10 and 11 can be separate pieces for convenience, or can be provided as a single combined unit, with the layers securely attached to each other. The use of separate mattress layers 10 and 11 allows for combinations of mattresses of different firmness and materials, in order to provide for the different needs of users, who can select the different mattress materials. For example, the mattress layers 10 and 11 can be made from gel memory foam, high-resilience foam, or natural latex cotton, respectively.

The bottom mattress layer 09 (FIG. 5) includes an upper surface layer 04 which is preferably formed from a waterproof material and covers the upper surface 16 of the bottom mattress layer 09. The sides of the bottom mattress layer 09 further comprise a band of lower strip tape 08 which extends around the periphery of the bottom mattress layer 09 below the upper positioning zipper 05 and is secured to the bottom mattress layer 09. Attached to the lower strip tape 08 is a lower mattress assembly positioning zipper 07, which extends around the periphery of the bottom mattress layer 09 and comprises upwardly facing zipper teeth that can mesh with the downwardly facing zipper teeth of upper cover zipper 02 (such as through the use of a zipper pull and slider). The lower positioning zipper 07 can be attached to the upper cover zipper 02 when the upper mattress layer 03 is removed, as shown in FIGS. 9-10 and described further below.

As shown in FIGS. 7-10, the present mattress can be converted into two different heights through the removal of the upper mattress layer 03. The upper mattress layer 03 is included in the mattress of FIGS. 7 and 8, thereby forming a mattress assembly which extends vertically higher than the assembly shown in FIGS. 9 and 10. The upper mattress layer 03 is not included in the mattress of FIGS. 9 and 10, so that the mattress assembly shown in these figures is vertically lower than the assembly shown in FIGS. 7 and 8.

The bottom mattress layer 09 can be a different type of mattress, or can be formed from a different material, than the upper mattress layer (03, 10, and 11). For example, the bottom mattress layer 09 can be a high-resilience foam, chain net spring, or pocketed coil mattress. The complete mattress assembly (FIGS. 7-8) can therefore comprise two mattresses having at least two different firmnesses.

Compared with a traditional integrated mattress, the present mattress has the following beneficial effect of reducing the cost and expenses to a user because the mattress components can be standardized while still allowing customization of the mattress. The mattress components can also be detached and replaced, so that it is convenient for the user to clean, air-dry, and replace the mattress. Mattress components can also be replaced with components made from different materials or constructions, so that the user can experience different comfort levels. The mattress thus has a flexible design and is convenient for hygienic care and replaceability.

The examples set forth herein are provided to illustrate certain concepts of the disclosure. The apparatus, devices, or components illustrated above may be configured to perform one or more of the methods, features, or steps described herein. Those of ordinary skill in the art will comprehend that these are merely illustrative in nature, and other examples may fall within the scope of the disclosure and the appended claims. While the above descriptions contain many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as examples of specific embodiments thereof.

The terms “above,” “below,” “higher, “lower,” “between,” and other terms of relative position or orientation as used herein refer to a relative position of one layer with respect to other layers, generally with reference to a support surface on which the present mattress is supported, such as a floor. “Vertical” and “horizontal” are likewise used in relation to such a support surface.

The term “comprise” and variations of the term, such as “comprising” and “comprises,” are not intended to exclude other additives, components, integers or steps. The terms “a,” “an,” and “the” and similar referents used herein are to be construed to cover both the singular and the plural unless their usage in context indicates otherwise. Ranges which are described as being “between” two values include the indicated values. 

What is claimed is:
 1. A dual core mattress, comprising: a) a removable upper cover having an upper surface, a lower surface, and an upper cover zipper portion, wherein the upper cover zipper portion extends around the lower periphery of the upper cover on a lower peripheral edge of the upper cover and includes downwardly extending zipper teeth; b) an upper mattress layer below the upper cover, the upper mattress layer having an upper surface and a lower surface; and c) a bottom mattress layer below the upper mattress layer, the bottom mattress layer having an upper surface and a lower surface, wherein the bottom mattress layer further comprises: (i) a waterproof material on the upper surface of the bottom mattress layer; (ii) an upper positioning zipper portion attached to an upper strip tape extending around the periphery of the bottom mattress layer at an upper end of the bottom mattress layer, the upper positioning zipper portion comprising upwardly extending zipper teeth; (iii) a lower positioning zipper portion attached to a lower strip tape extending around the periphery of the bottom mattress layer below the upper strip tape, the lower positioning zipper portion comprising upwardly extending zipper teeth; wherein the upper cover zipper portion can be removably secured to the upper positioning zipper portion when the upper mattress layer is positioned on the upper surface of the bottom mattress layer, and wherein the upper cover zipper portion can be removably secured to the lower positioning zipper portion when the upper mattress layer is positioned on the upper surface of the bottom mattress layer, thereby allowing the dual core mattress to be have two different vertical heights.
 2. The dual-core mattresses of claim 1, wherein the upper mattress layer and the lower mattress material have a different firmness.
 3. The dual-core mattresses of claim 1, wherein the upper mattress layer and the lower mattress layer are formed from different materials.
 4. The dual-core mattresses of claim 1, wherein the upper mattress layer comprises two separate pieces.
 5. The dual-core mattresses of claim 4, wherein each piece of the upper mattress layer is formed from a different material.
 6. The dual-core mattresses of claim 4, wherein each piece of the upper mattress layer has a different firmness.
 7. The dual-core mattresses of claim 4, wherein the upper mattress layer pieces each comprise a material selected from the group consisting of gel memory foam and natural latex cotton.
 8. The dual-core mattresses of claim 4, wherein the upper mattress layer pieces each comprise a material selected from the group consisting of gel memory foam and natural latex cotton.
 9. The dual-core mattresses of claim 1, wherein the bottom mattress layer comprises a high-resilience foam, chain net springs, or pocketed coils. 